EI a AT I BR 83-001 APPLIED MODEL : All models TROUBLE-SHOOTING GUIDE BRAKE SYSTEMS Problems or complaints involving the brake system will appear in a variety of ways. This Technical Bulletin deals with four types of major brake problems, as listed below, along with their solutions. Use this Bulletin as a handy reference to check and correct the cause of a problem encountered with the brake system. CONTENTS 1. POOR BRAKING ACTION ... 1-1, Proper pedal stroke . 1-2. Excessive pedal stroke . 1-3. Spongy brake pedal... 1-4, Poor braking action under forceful pedal pressure 2. BRAKE JUDDERS .. 3, UNEVEN BRAKING ACTION 4. BRAKE SQUEAKS....... Noaann ‘The Information inthis bulletin should not be interpreted as the bass forces unless 3 designated. Whenever you order spare parts, refer o the Spare Parts Bulletin, not to thie Technical Bulletin nian nd1. POOR BRAKING ACTION 1-1, Proper pedal stroke Excessive pedal pressure is required to stop the vehicle even though the stroke length of the brake pedal is adjusted properly. Condition Inspection Correction’ Water enters brake system after driving on sloppy roads or after vehicle washing, Apply brakes moderately while vehicle is in motion, to dry wet drum, shoe, rotor, pad, ete. by frictional heat. Brake shoe or pad jammed or hardened. Refinish frictional surface of brake shoe or pad with sandpa- per. Ifit is beyond repair, re place faulty parts Master/wheel cylinder oil pres- sure outside specified range. Replace faulty brake tubes, Replace NP or DP valve used on rear wheels.Flow chart Start POOR BRAKING ACTION Entrance of water into brake system after driving on sloppy roads. Yes Depress brake pedal while vehicle is in -—————+| motion to dry drum and shoe or rotor and pad by frictional heat. No Brake shoe/pad charred or hardened. | Yes | Sand contact surface of brake shoe No ee e or pad. Master/wheel cylinder pressure within specified range. Replace faulty brake tube, Replace rear wheel brake unit (NP, DP valves, etc.). Re-check. e Fa1-2. Excessive pedal stroke Condition Inspection Correction Leakage at hose/tube connec: tions. Leakage due to hose/tube break age. Tighten loose connections or re- place faulty parts. Replace faulty parts. Oy Leakage at broken master/wheel cylinder cup. Forcibly depress brake pedal and hold it there for several seconds. If brake pedal remains there, piston cup and cylinder are in good order; if it can be depressed to floor board, piston cup or cy- © | inder may be faulty. Replace faulty parts. i ‘Abnormal wear on brake shoe or pad (Increased pedal travel). Replace with new one. Flow chart Start POOR BRAKING ACTION Leakage around brake line, master cylinder, wheel cylinder, etc. Yes [ne ‘Abnormal wear on brake shoe or pad. Yes Tighten tube/hose connections, replace master/wheel cylinder cup or brake shoe/pad. q Re-check. EndCondition Inspection Correction ES OL = Sao Sree —} ws Excessive braking, as in down- hill driving (vapor lock or air bubbles in brake fluid caused by frictional heat). Replace with new brake fluid. Bleed air from brake system. Flow chart Start POOR BRAKING ACTION I Spongy brake pedal J Bleed air from brake system. I Re-check. End i Excessive braking as in downhill operation ("Vapor lock”). [ye Air bubbles in brake fluid due to frictional heat caused by excessive braking. I [ Replace brake fuid, + Re-check. End1-4. Poor braking action under forceful pedal pressure Flow chart Inspection Correction Insufficient braking power due to broken or loose vacuum hose, jammed check valve, leakage at booster or vacuum pressure leakage. Tighten loose connections or re- place faulty parts. Start Hard pedal operation Jamming check valve or leaking Master- Vac or vacuum pump Yes Replace faulty parts. heck. EndVibration, pulsation and/or shuddering are felt on the brake pedal when the brakes are applied. If such symptoms are forcefully produced, the dash panel, steering wheel, seats, engine hood, etc. will also vibrate. r Condition Inspection Correction Rust formation, score marks ‘Sand surface of brake drum, or heat spots on brake drum pad and shoe. If necessary, re- place with new ones. Surface runout not within specifications (disc rotor). Out-of-roundness not within specifications (brake drum). Unequal thickness in circum: ferential direction not within specifications (disc rotor). If it is beyond repair, replace faulty parts. Uneven or stepped wear on Sand surfaces of brake pad brake pad and/or lining, and/or lining. If necessary, replace with new ones.Micrometer Measuring the thickness of the disc rotor Brake drum gauge Measuring the out-of-roundness of the brake drum. For reference How to measure the thickness of the disc rotor or out-of-roundness of the brake drum. Using a micrometer or a brake drum gauge as shown, meas. ure the thickness of the disc rotor or out-of-round ness of the brake drum at eight to ten equally spaced points. The measuring points should be the surfaces with which the pad’s or shoe's center comes into con: tact. The difference in the maximum and minimum thickness of diameter should be less than 0.10 mm (0.0039 in).Flow chart Start Rotate tires and road wheels or road Yes, There is no roughness or pulsation wheel mounting bolt holes, or test. = ["__*! when brakes are applied. vehicle on a dry, smooth road. To conduct road test, drive vehicle and apply brakes. (Do not bring vehicle Y toa stop.) Wait about one minute Re-check, before applying brakes. Repeat above test several times. No End Oil on brake shoe or pad or indication of heat spots, or uneven or stepped Yes [Sand surface of brake shoe or pad. If wear. [| necessary, replace with new one. No l + Rust, score marks or heated spots on Re-check. disc rotor or drum. No ¥ + End Surface runout or thickness of disc rotor or out-of roundness of brake drum outside specifications. Yes | If still outside specifications, replace No *| faulty part with new one. + Check suspension bushings, tire runout, ete. and correct, Re-check. End Note: If brakes are faulty, the vehicle will frequently shake wi Re-check. End operation even after the brake pedal has been released. Minor abnormal s, however, can cause the brake pedal to judder.When the brake pedal is depressed, the vehicle pulls to one side with either the rear wheels in “unlocked” or the effort required to hold the steering wheel increased temporarily. Condition Inspection Correction Brake pad or lining charred. (Excessive braking, as in downhill driving) ‘Sand surface of brake pad or lining, If beyond repair, replace with new one. Oil or water on brake pad or lining. Repair leaking parts (wheel cylinder, rear axle oil seal, hub grease seal, etc.) Dry water-wet part by applying brakes. Unequal contact of brake pad or lining. Sand surface of brake pad or lining. If necessary, replace with new one, Dragging brakes. Adjust or replace faulty parts Heat spots, roughness or foreign matter on brake pad or shoe. Sand surface of brake pad or shoe. If necessary, replace with new one, Wheel cylinder Improper operation Replace with new one. Wheel cylinder, back plate, caliper, etc, Loose bolts. Improper operation. Tighten bolts. Apply grease, adjust or replace, as necessary. 10Flow chart Start When brakes are applied, vehicle pulls to one side with rear wheels unlocked or steering wheel tends to turn, + 7 ee Yes Adjust tire pressure, or replace or ir re/ Wi == Inequal tire pr rotate tires, Incorrect wheel alignment or excessive Yes ‘Adjust wheel alignment or correct play in suspension or steering linkage faulty parts to remove excessive play. No ct: + Yes +] Brake pad or shoe charred | Sand surface of brake pad or shoe, or replace with new one. No Repair faulty parts (wheel cylinder, rear axle oil seal, wheel hub grease >| seal, etc.) Also clean out rotor and drum. + Yes Dry parts wet with water by applying Oil or water on brake pad or shoe brakes. No brakes Adjust or replace. No $$$] Yes Uneven contact of brake shoe or pad | +! Equally sand surface of brake shoe or pad a Recheck. Dragging * Note: End of lining’s friction and produces unequal braking on left and right brakes (Brake fading) x Excessive braking (as in downhill operation) decreases the coefficient ”4. BRAKE SQUEAKS Inspection and maintenance (1) The brake squeaks or clicks when the brake pedal is depressed, (2) A snapping or grinding noise is heard when the brake pedal is completely released. (A squeaking noise occurs when the brake drum and shoe or the disc rotor and pad ces- onate with one another.) Part/Unit Inspection standard Remedy Brake shoe or pad Discolored, glazed and hardened. Replace faulty part. (Lightly sand drum rotor.) Improper contact {contact area extremely small). ‘Sand surface of brake shoe or pad. If necessary, replace with new one. ability) of piston, Back plate Lack of grease on frictional Apply recommended grease (ledge) surfaces of back plate and | (Wipe excess grease) brake shoe. Drum brake or disc rotor | Runout outside specifications. Repair wheel bearing. If still out side specifications, replace faulty part. All parts indicated above No abnormalities indicated above. | Grind edge of brake pad or shoe. Apply thin coat of PBC grease (genuine) to rear (iron plate) side of pad. Cylinder body Improper operation (poor return- | Apply coat of recommended ability) of cylinder body and grease or replace faulty parts. yoke. Wheel cylinder Improper operation (poor return- | Remove rust or replace faulty parts. 2Bl (1) Checking for contact of the disc rotor and pad or brake drum and shoe ® Apply a thin coat of chalk powder to the surface of the disc rotor or the inner surface of the brake drum, @® Turn the disc rotor or the brake drum one to two complete rotations while pressing the brake pad (shoe) against the rotor (drum). Check the contact surface of the brake pad or the brake shoe. @ If it is less than 70% or if it is distributed to only part of the surface, refinish the brake pad or brake shoe with sandpaper until more than 70% of the entire surface area comes into contact with the dise rotor or the brake drum. How to check/service brake parts | Apply chalk ponder to the surface ofthe dite rotor \ Donny aut Dummy nut ia 140 2 rotations Apply brake ‘Apply brake (2) Cutting off the edge of the brake pad or shoe Partially cutting-off the brake pad or shoe helps prevent unequal contact of the shoe or pad. Excessive cutting-off can adversely affect the braking performance. Point to be cut off (Cut off ‘entire edge of brake p36) Rotating direction of brake drum a A 05-1 mm e442 (0.020"0.039 in t ae A 98-1mm (0.020 "0.039 in) E a Section AA 08-1 mm {| (0.020 "0.039 in) f fe | - Equally eut off a Section AA. 0,039 in) of brake pad's edges cutoff edge (shown by arrow) fof leecing brake shoe (3) Others © Grooving the surface of the brake pad or shoe is another method used to help eliminate brake “squeaks”; however, it can adversely affect the service life of the part and the brake performance. ® Use of commercially available spray (non-genuine parts) which reduces “squeaks” is not recom- mended, since it causes an extreme reduction in braking performance. 13Flow chart (1) When brakes are applied 4 Start Squeak or click is heard. ¥ discolored. Brake shoe or pad hardened or No + f a, ves) Replace faulty part. Sand surface of drum rotor. Lack of grease on contact surfaces of brake shoe and back plate. No + f Unequal or partial contact of brake shoe and brake drum or brake pad and disc rotor. Yes |—=— ‘Apply coat of recommended grease. Yes _| Sand surfaces of parts affected or, if beyond repair, replace faulty parts. ———— + oA Repair wheel bearing. Runout of brake drum or disc rotor | _Y*_! if itis in good order, replace faulty outside specifications. [n° Cut off part of brake pad’s or shoe's edge or apply thin coat of grease to, f¢ rear surface of brake pad. |_ Recheck, End parts, ~o=i a (2) When brakes are not applied Start Snapping or grinding noise Parking brake not returned com- pletely or not properly adjusted. Yes ‘Adjust parking brake. Re-check. No i [Disc brake) Improper operation of torque member, slide pin, yoke or cylinder body (poor returnability). e [Drum brake] Improper operation of wheel cylinder piston (poor returnability). No [ve Apply coat of recommended grease or replace faulty parts. Remove rust or replace faulty parts. Re-check. e Ee ¥ Other problems. 15OTe